Related Manuals for Xmotos XZ 250R
Summary of Contents for Xmotos XZ 250R
- Page 1 OPERATING INSTRUCTION MANUAL 2011 - 2012 DIRT BIKE MOTOCROSS MOTARD XZ 250R XZ 250RM XZ 250R V4 OWNER’S MANUAL VER.2 10/2011...
- Page 2 XZ250R - LC / ZS XZ250RM XZ250R V4 Owner’s Manual This manual should be considered a permanent part of the motorcycle and should remain if it is resold. This manual contains the latest product information available before printing. XGroup Corporation reserves the right to make changes at any time without notice and without incurring any obligation.
- Page 3 It shall be acceptable to stop manufacturing a certain model without prior notice. In the event of such modifications, please ask your local Xmotos dealer for information...
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Page 4: Important Warranty Information
Xmotos obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective parts and Xmotos does not assume or authorize anyone to assume for them any other obligation. No service center and/or dealer is authorized to modify this warranty. -
Page 5: Table Of Contents
CONTENTS IMPORTANT WARRANTY INFORMATION SUSPENSION SYSTEM 48 - 51 INTRODUCTION FRONT SUSPENSION INSPECTION IMPORTANT SAFETY INFORMATION 07, 08 FRONT SUSPENSION ADJUSTMENT 48 - 49 SAFETY INFORMATION FOR PARENTS REAR SUSPENSION INSPECTION 10, 11 SAFETY LABEL INFORMATION REAR SUSPENSION ADJUSTMENT 50, 51 12 - 15 COMPONENT LOCATIONS 52 - 54... -
Page 6: Introduction
Your Xmotos motorcycle was designed as a recreational motorcycle for off-road use only by a single rider. This motorcycle is ideal for riders with basic experience. (Off-Road) Your Xmotos motorcycle was designed as an on road motorcycle and to be used only by a single rider. (On-Road) This manual has information regarding four (4) different types of models. -
Page 7: Important Safety Information
IMPORTANT SAFETY INFORMATION Your personal safety, and the safety of those around you, is extremely important. Operating this motorcycle safely is an important responsibility. XGroup Corporation has provided operating procedures and other information on labels and in this manual to help you make informed decisions about safety. This information will alert you to potential hazards that could harm you or others. - Page 8 Never ride your motorcycle without a helmet. Even a crash at slow speed can result in a fatal head injury if you are not wearing a helmet. Xmotos strongly recommends wearing helmets that have been certified for safety by helmet testing organizations that are independent from the helmet manufacturer.
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Page 9: Safety Information For Parents
As a parent it is your responsibility to be sure that the motorcycle is properly maintained and kept in safe operating condition. Modifying this motorcycle or using parts not manufactured by Xmotos can make your motorcycle unsafe. Before you consider making any modifications or adding an accessory, please read the following information carefully. -
Page 10: Safety Label Information
Others will provide important safety and maintenance information. Please read them carefully and do not remove them. If your label wears off from riding or becomes hard to read, contact your Xmotos dealer for a replacement. - Page 11 Others will provide important safety and maintenance information. Please read them carefully and do not remove them. If your label wears off from riding or becomes hard to read, contact your Xmotos dealer for a replacement.
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Page 12: Component Locations
COMPONENT LOCATIONS When you ride a motorcycle off-road, you need to be able to operate the throttle, clutch, brakes, and other controls without stopping to look at them. Please read this section carefully before you ride your motorcycle. This section of the manual will show the location and operation of all the basic controls of your motorcycle. Front Master Cylinder &... - Page 13 COMPONENT LOCATIONS (RM) When you ride a motorcycle on-road, you need to be able to operate the throttle, clutch, brakes, and other controls without stopping to look at them. Please read this section carefully before you ride your motorcycle. This section of the manual will show the location and operation of all the basic controls of your motorcycle. Engine Start Switch Ignition Key Engine Stop Switch...
- Page 14 COMPONENT LOCATIONS (OFF-ROAD) Battery CDI Box Spark Plug Kick Starter Oil Filter Rear Brake Pedal Air Filter Fuel Valve Chassis Number Drive Chain Shift Lever Engine Number Side Stand...
- Page 15 COMPONENT LOCATIONS (ON-ROAD) Battery CDI Box Kick Starter Ignition Coil Oil Filter Rear Brake Pedal Spark Plug Fuel Valve Air Filter Chassis Number Drive Chain Engine Number Shift Lever...
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Page 16: Serial Number Locations
SERIAL NUMBER LOCATIONS VIN – Chassis Number The VIN number is located in one of three places on the chassis. Right Side of frame. Left side of frame. Steering head tube. Write this number in the VIN box on page 3. Engine Model &... -
Page 17: Handlebar Lever Controls
HANDLEBAR LEVER CONTROLS Clutch Lever The clutch lever is located on the left side of the handlebar. Hand Brake Lever & Throttle The hand brake lever and throttle is mounted on the right side of the handlebar. The adjusting screw can be used to change the basic position of the brake lever. - Page 18 OPERATING CONTROLS (ON-ROAD) Left Handlebar Switches Electric Start Button Use this button to operate the starter motor. With the key ignition switch in the “ON” position, the engine stop switch in the “RUN” position , and the transmission in the neutral position, pull the clutch lever and push the electric start button to start the engine.
- Page 19 OPERATING CONTROLS Key Ignition Switch The ignition key is used to supply power from the battery to the electrical components of the motorcycle in the “ON” position . Turn the switch to the “OFF” position when you are finished riding, or if you wish to stop the engine.
- Page 20 OPERATING CONTROLS Choke Lever (XZ250R – LC / ZS) When pulling the choke lever fully toward the top cylinder in the carburetor is opened. Through this cylinder, the engine can take in additional fuel. This results in a rich fuel and air mixture, which is needed for a cold start. When pushing down the chock lever, the cylinder is closed again.
- Page 21 OPERATING CONTROLS Shift Lever (V4 / RM) The shift lever is on the left side of the engine. The gear positions are shown in the illustration on page 28. Foot Brake Lever (V4 / RM) The brake lever is located on the right side of the engine.
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Page 22: Guages, Indicators & Display
GUAGES, INDICATORS & DISPLAY Speedometer and Odometer The digital speedometer indicates the road speed of the motorcycle. The read-out displays the motorcycle road 1 2 3 4 5 6 speed in increments of one kilometer (or mile) per hour. In the speedometer face is the electronic odometer and KM/H 00000.0 one trip meter. -
Page 23: Before Riding
BEFORE RIDING Before you ride, you must be absolutely sure that you and your motorcycle are ready to ride. To help you get prepared, this section of the manual will discuss how to evaluate your riding readiness and how to perform our recommended ore-ride inspection of your motorcycle. -
Page 24: Is The Motorcycle Ready To Ride
Brakes – Step on the rear brake lever and squeeze the front brake lever to be sure the brakes are working properly. Remember, be sure to take care of any problems you find or have your Xmotos dealer correct it before you ride. -
Page 25: Basic Operation & Riding
BASIC OPERATION & RIDING This section of the manual gives basic information on how to begin riding your motorcycle. In this section we will cover how to start and stop the engine, how to use the throttle and brakes, how to use the clutch and shift gears, and things you need to do when you are finished riding. -
Page 26: Engine Starting Procedure
BASIC OPERATION & RIDING STARTING & STOPPING THE ENGINE Always follow the proper starting procedure as described below. STARTING PROCEDURE (ELECTRIC START) Starting When the Engine Is Cold 1. Turn the key switch to the “ON” position. 2. Make sure the transmission is in the neutral position. 3. -
Page 27: Flooded Engine
BASIC OPERATION & RIDING FLOODED ENGINE If the engine fails to start after repeated attempts, it may be flooded with excess fuel. Follow the steps below to clear a flooded engine. 1. Press the engine stop switch and hold it. 2. -
Page 28: Shifting Gears
SHIFTING GEARS This motorcycle has five (5) forward gears for LC / ZS / V4 series and six (6) forward gears for RM – (V4 – Optional) series. (RM - (V4 - Optional)) To start riding, after the engine has been warmed up and the side stand raised: (LC / ZS / V4) 1. -
Page 29: Braking Technique
BRAKING TECHNIQUE This section will cover basic braking technique for your motorcycle. To slow or stop the motorcycle, squeeze and hold the clutch lever and apply the front brake lever and rear brake pedal firmly and smoothly. If your speed is reduced a significant amount, you may need to downshift to a lower gear. Gradually increase your braking pressure as you feel it is needed. -
Page 30: Maintaining Your Dirt Bike
In this section you will also find important safety precautions, information on oils, and tips for keeping your Xmotos motorcycle looking good. -
Page 31: Maintenance Schedule
Xmotos dealer. If you decide to do your own maintenance, use only genuine replacement parts that you have purchased from an Xmotos dealer or parts purchased directly from Xmotos. This will ensure the best quality and reliability for your motorcycle. -
Page 32: Periodic Maintenance Schedule
MAINTENANCE SCHEDULE PERIODIC MAINTENANCE SCHEDULE After 10 After 25 Service Hours or Hours or After A clean and maintained motorcycle saves time and money! 1000 KM 2500 KM 5000 KM Check engine oil level Change engine oil and oil filter USE ONLY PETRONAS OIL, SEE Pg. - Page 33 MAINTENANCE SCHEDULE PERIODIC MAINTENANCE SCHEDULE Before After For Cross VITAL CHECKS & CARE PROCEDURES TO BE CONDUCTED BY THE Once a Each Every Country year OWNER OR THE TECHNICIAN(S) Start Cleaning Check oil level Check brake fluid level ...
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Page 34: Basic Maintenance Precedures
The engine in your motorcycle has been designed to run on any gasoline with a pump octane rating of 86 or higher. Most service stations will display the octane rating above each pump. Although it is not required, Xmotos recommends use of gasoline with a 90 octane rating or higher to ensure maximum performance and reliability. -
Page 35: Cooling System
4. Make sure the overflow tube is connected and not clogged. 5. Check the radiator fins to make sure they are not clogged. 6. If you do notice any leaks at any time, consult your nearest Xmotos dealer. WARNING Coolant Replacement... -
Page 36: Engine Oil
BASIC MAINTENANCE PROCEDURES ENGINE OIL Using proper oil, and regularly checking, adding and changing oil will help extend the service life of your engine. Even the best oil wears out and becomes thinner. Changing oil helps get rid of dirt and deposits in the engine. - Page 37 BASIC MAINTENANCE PROCEDURES ENGINE OIL Cont. CHECKING & ADDING OIL 1. Start and run the engine at idle for 3-5 minutes, then stop it. 2. Wait about 2-3 minutes to allow the oil to properly distribute itself in the engine. 3.
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Page 38: Changing Oil & Filter
BASIC MAINTENANCE PROCEDURES CHANGING OIL & OIL FILTER 1. Start and run the engine at idle for 3-5 minutes, then stop 2. Stand the motorcycle on a straight level surface so that it is not leaning to either the right or left & support it. 3. -
Page 39: Changing Air Filter
Always replace the air filter with a genuine Xmotos filter specifically designed for your model or a filter of equal quality. Failure to maintain the filter can/may cause engine wear or damage, expensive repairs, low engine power, low fuel mileage, carbon build up on valves and foul the spark plug. -
Page 40: Throttle System
BASIC MAINTENANCE PROCEDURES THROTTLE THROTTLE FREEPLAY A. Throttle free-play should be 3 – 5 mm (0.10 – 0.20 in) B. If your throttle has more play than specified, adjustments need to be made. Follow the steps below: C. Minor adjustments are generally made with the upper adjuster. -
Page 41: Engine Idle Speed
9. The idle must be at 1500 ± 100 Rpm. 10. DO NOT adjust the air/fuel mixture screw . It has Fig. 2 V4 / RM been set from the factory. This should only be adjusted by an Xmotos dealer. -
Page 42: Clutch System
BASIC MAINTENANCE PROCEDURES CLUTCH SYSTEM In order to ensure the best performance and durability from the clutch, always be sure you have proper clutch free-play. Free-play is needed to ensure that the clutch has room for wear. A clutch with no free-play will begin to slip as the discs wear down. - Page 43 5. Gradually release the clutch lever and open the throttle. XZ250R - LC The motorcycle should move smoothly and accelerate gradually. 6. If you cannot get the proper adjustment, see you Xmotos dealer or service center. XZ250R - ZS XZ250R V4 / RM...
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Page 44: Spark Plug
5. Using moderate grit sandpaper (220-400), sand between the center electrode and the side electrode until all carbon and oil deposits are removed. Xmotos recommends that you use a spark plug cleaner or a new spark plug if the plug is very dirty. -
Page 45: Braking System
BASIC MAINTENANCE PROCEDURES BRAKEING SYSTEM Your motorcycle is equipped with hydraulic disc brakes on both the front and rear wheels. Hydraulic brakes require brake fluid for its operation. Both front and rear brakes have a brake fluid reservoir built into the master cylinders. -
Page 46: Adding Brake Fluid
6. Press the foot brake lever to be sure the brakes are working properly. 7. Check the brake hose and brake caliper for leaks. If you are unsure how to re-assemble a part, contact your Xmotos dealer for servicing information and/or servicing. NOTICE Be very careful not to spill brake fluid on painted surfaces or it will damage the paint. -
Page 47: Brake Pads
Xmotos dealer for a possible bad brake caliper. 4. If you are unsure how to replace the brake pads, please contact your nearest Xmotos dealer for assistance, or schedule your motorcycle for servicing. BLEEDING THE BRAKE SYSTEM Because the brake system utilizes fluid, any air bubbles inside the brake system will cause you to lose braking efficiency. -
Page 48: Suspension System
Loose, worn or damaged suspension components may affect the stability and handling of your motorcycle. If any of the suspension components seem to be worn or damaged, see your Xmotos dealer for service and/or inspection. Your Xmotos dealer is the most qualified to determine whether or not replacement parts or service is required. -
Page 49: Front Suspension Adjustment
Loose, worn or damaged suspension components may affect the stability and handling of your motorcycle. If any of the suspension components seem to be worn or damaged, see your Xmotos dealer for service and/or inspection. Your Xmotos dealer is the most qualified to determine whether or not replacement parts or service is required. -
Page 50: Rear Suspension Adjustment
BASIC MAINTENANCE PROCEDURES REAR SUSPENSION Cont. The rear suspension of your motorcycle has 3 different adjustment points. It comes from the factory set to the softest setting. If you wish to make the rear suspension harder, follow the procedure below. Adjusting the rear shock is not hard, but like the front forks, changes should be made one at a time to gain an accurate understanding of how they affect the bike. - Page 51 DO NOT TRY TO REPAIR THE SHOCK. 4 positions. IF REPAIR IS NECESSARY, TAKE THE 3. To adjust to the standard position, turn the adjuster MOTORCYCLE TO AN XMOTOS DEALER. clockwise until it will no longer turn (DO NOT FORCE). This is the full hard setting.
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Page 52: Rims, Tires & Spokes
Look for a wobble in the wheel. If a wobble is evident, the wheel is not“true”. See your Xmotos dealer or local motorcycle shop for inspection. TIRE AIR PRESSURE Properly inflated tires will provide you with the best combination of handling, tread life, and riding comfort. -
Page 53: Tire Inspection
Always use replacement tubes that are the same size as the original. We recommend that you have tubes changed at your local Xmotos dealer or your local motorcycle shop. Replacing a tube requires removal and installation of the wheel. Anytime you have a tube replaced, perform the tire inspection listed at the top of this page. -
Page 54: New Tire Break-In Period
This indicates that the chain is worn beyond its service limit. 5. Inspect the front and rear sprockets for excessive wear or damage. Refer to the illustration at the top of page 42. If needed, replace any worn or damaged sprockets. See your Xmotos dealer for assistance. NOTICE... -
Page 55: Drive Sprocket Inspection
3. If the roller has been worn down beyond the two points marked in Fig. 1, then the roller(s) must be replaced. 4. If you cannot or do not know how, take the motorcycle to a Xmotos dealer for service. CAUTION NEVER RIDE YOUR MOTORCYCLE IF THE ROLLERS ARE WORN EXCESSIVELY. -
Page 56: Chain Slider Inspection
BASIC MAINTENANCE PROCEDURES CHAIN SLIDERS CHAIN SLIDER INSPECTION 1. Check the slider for wear Fig. 1 2. If the wear limit has been reached Fig. 3, it must be replaced. Fig. 1 1. Check the guide slider for wear Fig 2. 2. -
Page 57: Chain Adjustment
BASIC MAINTENANCE PROCEDURES CHAIN ADJUSTMENT Follow the procedure below to adjust the drive chain slack. Be sure that you are parked on a level surface and the engine is turned OFF. CHAIN ADJUSTMENT 1. Loosen the rear axle nut 2. Loosen the lock nut on both right and left side. -
Page 58: Chain Removal & Replacement
3. Inspect the drive chain for possible wear or damage. Replace the drive chain if it has any damaged rollers, loose fitting links, or otherwise appear unserviceable. 4. Inspect the sprockets for wear or damage. Xmotos recommends that you replace the sprockets when you install a new drive chain. -
Page 59: Troubleshooting
No hard firmness in the kick start lever means you have poor compression. Is the compression normal? - Valve stuck open/seized or improper valve timing (see your Xmotos dealer) - Worn cylinder wall and/or piston rings (replace engine) - Page 60 Cylinder Compression Inspection - Check the cylinder compression. Is the engine compression normal? - Valve stuck open/seized or improper valve timing (see your Xmotos dealer) - Worn cylinder wall and/or piston rings (replace engine) - Leaking or damaged cylinder head gasket (see your Xmotos dealer)
- Page 61 - Excessive carbon buildup in the combustion chamber Ignition Timing Inspection - See your local Xmotos dealer or motorcycle repair shop to have the ignition timing and engine lubrication system inspected. Only attempt these procedures if you are qualified and have the proper tools needed.
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Page 62: Poor Performance At High Speed
- Carburetor is not serviced frequently enough, contaminated fuel Ignition Timing & Valve train Inspection - See your local Xmotos dealer or motorcycle repair shop to have the ignition timing inspected. Only attempt these procedures if you are qualified and have the proper tools needed. - Page 63 TROUBLESHOOTING POOR HANDLING Steering is heavy - Steering stem nut too tight - Damaged steering head bearings - Check tire pressure Either wheel has a Wobble - Excessive wheel bearing play - Bent Rim - Improperly installed wheel hub - Damaged swing-arm - Bent frame - Loose or broken spokes - Old tires with “dry-rot”...
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Page 64: Resolving The Unexpected
RESOLVING THE UNEXPECTED GENERAL GUIDELINES If you encounter trouble during a ride, the first thing you should do is stop as soon as it is safely possible. Do not continue to ride if you have a flat tire, if you hear an unusual noise, or if your motorcycle just does not feel right. - Page 65 Sometimes crash damage is hidden or not immediately apparent. Once you get home, go over your motorcycle thoroughly and fix any problems that you find. Also, be sure to have your Xmotos dealer inspect the frame and suspension after a serious crash.
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Page 66: Torque Specifications
TORQUE SPECIFICATIONS... - Page 67 TORQUE SPECIFICATIONS Torque Torque Name Notes Name Notes N•m ft•lbs N•m ft•lbs Brake hose bolt 32.4 Seat bolts 24.4 Clutch holder Brake hose bolt 32.5 Triple clamp (upper) Exhaust mounting bolt 24.4 Triple clamp (lower) Sub-frame bolt (lower) 33.8 Handlebar riser (lower) 37.8 Shock spring lock nut Handlebar riser (upper)
- Page 68 TORQUE SPECIFICATIONS (LC) XZ250R - LC Torque Name Notes N•m ft•lbs Engine mount (front) Oil drain cap 17.5 Engine mount (lower) 40.5 Sprocket bolts 16.2 Swing arm nut Engine mount (upper) Engine mount (top) Brake lever pivot bolt 29.7 3, 4 Kick starter bolt 33.7 Exhaust nut...
- Page 69 TORQUE SPECIFICATIONS (ZS) XZ250R - ZS Torque Name Notes N•m ft•lbs Engine mount (front) Oil drain bolt 17.5 Engine mount (lower) 40.5 Sprocket bolts 16.2 Swing arm nut Engine mount (upper) Engine mount (top) Brake lever pivot bolt 29.7 3, 4 Kick starter bolt 33.7 Exhaust nut...
- Page 70 TORQUE SPECIFICATIONS (V4 - RM) XZ250R – V4 / RM Torque Name Notes N•m ft•lbs Engine mount (top) DO NOT REMOVE //// //// //// Engine mount (upper) 40.5 Sprocket cover bolts 16.2 Sprocket bolt 48.6 Engine mount (lower) 40.5 Oil filter screen 13.5 Oil drain bolt 17.5...
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Page 71: Specifications
SPECIFICATIONS XZ250R - LC XZ250R - ZS XZ250R V4 / RM Engine LC170MM-2A ZS169MM ZS177MM 4 - Stroke Water Cooled / 4 Design 4 - Stroke Water Cooled / 2 Valve / Single Camshaft Valve / Single Camshaft Displacement 249.4 mL 243 mL 249.6 mL Bore / Stroke... - Page 72 Xmotos T8 (Z) Series, Dual Adjustable Forks Wheel Travel Front Xmotos T7 (S) Series Dual Adjustable 245 mm // T8 (Z) Series 275 mm Rear Xmotos T8 (Z) Series 110 mm Rear Suspension Xmotos T8 (Z) Series, Dual Adjustable with Piggyback Reservoir 500mm with Linkage...
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Page 73: Wiring Schematics
WIRING SCHEMATIC (OFF-ROAD / LC-ZS-V4) - Page 74 WIRING SCHEMATIC (ON-ROAD / RM)
- Page 75 WIRING SCHEMATIC (ON-ROAD / RM) XZ250RM Model Revised 03/2011...
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Page 76: Maintenance Records
MAINTENANCE SCHEDULE RECORD Odometer or Hour Reading Odometer or Hour Reading Odometer or Hour Reading 00,000 Dealer Stamp Dealer Stamp Dealer Stamp Date Date Date Signature Signature Signature Odometer or Hour Reading Odometer or Hour Reading Odometer or Hour Reading Dealer Stamp Dealer Stamp Dealer Stamp... -
Page 77: Notes
NOTES... - Page 78 NOTES...